Apparatus for bonding substrates having a substrate holder with holding fingers and method of bonding substrates

ABSTRACT

A substrate bonding apparatus includes a substrate susceptor to support a first substrate, a substrate holder over the substrate susceptor to hold a second substrate, the substrate holder including a plurality of independently moveable holding fingers, and a chamber housing to accommodate the substrate susceptor and the substrate holder.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

Korean Patent Application No. 10-2018-0103029, filed on Aug. 30, 2018,in the Korean Intellectual Property Office, and entitled: “Apparatus forBonding Substrates and Method of Bonding Substrates,” is incorporated byreference herein in its entirety.

BACKGROUND 1. Field

Embodiments relate to a substrate bonding apparatus and a substratebonding method, and more particularly, to a substrate bonding apparatusand a substrate bonding method, by which a semiconductor device ismanufactured at low costs and with improved precision.

2. Description of the Related Art

For the development of a semiconductor device having a three-dimensional(3D) connection structure, two semiconductor wafers need to be preciselybonded with each other. When the two semiconductor wafers are veryprecisely bonded together, semiconductor devices providing highperformance, while having small sizes, can be manufactured at low costsand with high reliability. Although various methods to bond twosemiconductor wafers together are being developed, further bondingprecision is necessary.

SUMMARY

According to an aspect, there is provided a substrate bonding apparatusincluding a substrate susceptor configured to support a first substratedownwards, a substrate holder located over the substrate susceptor andconfigured to hold a second substrate, and a chamber housing configuredto accommodate the substrate susceptor and the substrate holder, whereinthe substrate holder includes a plurality of holding fingers that areoperable independently.

According to another aspect, there is provided a substrate bondingapparatus including a substrate susceptor configured to support a firstsubstrate downwards, a substrate holder located over the substratesusceptor and configured to hold a second substrate, and a pressingfinger arranged at a location corresponding to a center of the secondsubstrate and configured to press the second substrate toward the firstsubstrate, wherein the substrate holder is configured to release holdingof the second substrate after a spontaneous bonding propagation betweenthe first substrate and the second substrate is sufficiently conductedand an edge of the second substrate approaches an edge of the firstsubstrate.

According to yet another aspect, there is provided a substrate bondingmethod including arranging a substrate holder holding a second substratedisposed thereon, on a substrate susceptor having a first substratedisposed thereon, such that the first and second substrates are alignedwith each other, bringing a center of the second substrate to contactthe first substrate, allowing a spontaneous bonding propagation betweenthe first substrate and the second substrate to be sufficientlyconducted, bringing the second substrate close to the first substratewhile maintaining holding of the second substrate, and releasing theholding of the second substrate.

According to yet another aspect, there is provided a substrate bondingapparatus, including a substrate susceptor to support a first substrate,a substrate holder over the substrate susceptor to hold a secondsubstrate, and a pressing finger at a center of the substrate holder,the pressing finger being moveable toward the substrate susceptor topress the second substrate toward the first substrate, wherein thesubstrate holder is to release holding the second substrate after aspontaneous bonding propagation between the first substrate and thesecond substrate is sufficiently conducted and an edge of the secondsubstrate approaches an edge of the first substrate, and wherein thesubstrate holder is to release holding of the second substrate aftermoving toward the first substrate until a distance between the edge ofthe second substrate and the edge of the first substrate is about 1 μmto about 50 μm.

BRIEF DESCRIPTION OF THE DRAWINGS

Features will become apparent to those of skill in the art by describingin detail exemplary embodiments with reference to the attached drawings,in which:

FIG. 1 illustrates a side view of a substrate bonding apparatusaccording to an embodiment;

FIG. 2 illustrates a bottom view of a substrate holder included in thesubstrate bonding apparatus of FIG. 1 ;

FIGS. 3A through 3E illustrate conceptual views of stages in a method ofbonding a first substrate and a second substrate together, according toan embodiment;

FIGS. 4A and 4B illustrate conceptual views of stages in a method ofbonding a first substrate and a second substrate together, according toanother embodiment;

FIGS. 5A through 5E illustrate conceptual views of stages in a method ofbonding a first substrate and a second substrate together, according toanother embodiment;

FIGS. 6A through 6E illustrate conceptual views of stages in a method ofbonding a first substrate and a second substrate together, according tostill another embodiment;

FIG. 7 illustrates a conceptual view of distortion on a substrate whenholding of a second substrate is released without bringing the edge ofthe second substrate close to a first substrate by using holdingfingers;

FIG. 8 illustrates a schematic diagram of a method of aligning a firstsubstrate with a second substrate, according to an embodiment;

FIG. 9 illustrates a side view of a holding finger according to anembodiment;

FIG. 10 illustrates a side view of a holding finger according to anotherembodiment;

FIG. 11 illustrates a side view of a holding finger according to anotherembodiment;

FIG. 12 illustrates a side view of a substrate bonding apparatusaccording to another embodiment;

FIG. 13 illustrates a schematic diagram of a first substrate and asecond substrate bonded with each other, according to an embodiment; and

FIG. 14 illustrates a magnified cross-sectional view of portion XII ofFIG. 13 .

DETAILED DESCRIPTION

Hereinafter, embodiments will be described more fully with reference tothe accompanying drawings, in which exemplary embodiments are shown.

FIG. 1 is a side view of a substrate bonding apparatus 100 according toan embodiment.

Referring to FIG. 1 , the substrate bonding apparatus 100 may include asubstrate susceptor 120, a substrate holder 110 located over thesubstrate susceptor 120, and a chamber housing 130 that accommodates thesubstrate susceptor 120 and the substrate holder 110.

The chamber housing 130 may surround the substrate susceptor 120 and thesubstrate holder 110. According to some embodiments, a vacuum pressureor an atmospheric pressure may be formed within the chamber housing 130.A first substrate W1 and a second substrate W2 respectively supported orheld by the substrate susceptor 120 and the substrate holder 110 may beprotected by the chamber housing 130.

The chamber housing 130 may have a wall 132 and an opening 134, e.g.,the opening 134 may extend through the wall 132. The first and secondsubstrates W1 and W2 may be carried into or carried out of the chamberhousing 130 via the opening 134. The opening 134 may be sealed asnecessary to protect the inside of the chamber housing 130 from anexternal environment.

The substrate susceptor 120 may support the first substrate W1 seatedthereon. According to some embodiments, the first substrate W1 may be asingle crystal substrate. According to some embodiments, the firstsubstrate W1 may be a silicon wafer.

The substrate susceptor 120 may include a susceptor body 122 and a firstsubstrate fixing unit 124. For example, as illustrated in FIG. 1 , thefirst substrate fixing unit 124 may be within the susceptor body 122,e.g., a top surface of the first substrate fixing unit 124 may beexposed by and substantially level with a top surface of the susceptorbody 122. The substrate susceptor 120 may be configured to fix the firstsubstrate W1 by using, e.g., a vacuum or an electrostatic force. Whenthe substrate susceptor 120 fixes the first substrate W1 by using avacuum, the first substrate fixing unit 124 may be configured to form alower pressure than an ambient pressure at a bottom surface of the firstsubstrate W1. When the substrate susceptor 120 fixes the first substrateW1 by using an electrostatic force, the first substrate fixing unit 124may be configured to generate an electrostatic force allowing the firstsubstrate W1 to be fixed.

The substrate holder 110 may be provided to face the substrate susceptor120, e.g., the first substrate W1 may be between the substrate susceptor120 and the substrate holder 110. The substrate holder 110 may hold thesecond substrate W2. The substrate holder 110 may hold the secondsubstrate W2 from the top of the second substrate W2, e.g., the secondsubstrate W2 may be between the first substrate W1 and the substrateholder 110. In other words, the substrate holder 110 may contact anupper surface of the second substrate W2 and hold the second substrateW2. According to some embodiments, the second substrate W2 may be asingle crystal substrate. According to some embodiments, the secondsubstrate W2 may be a silicon wafer.

FIG. 2 is a bottom view of the substrate holder 110.

Referring to FIGS. 1 and 2 , an outer circumference of a substrateholder body 112 may be generally a circle. A plurality of holdingfingers 114 may be arranged substantially at regular intervals along theouter circumference of the substrate holder body 112. Angles θ formedbetween each two adjacent holding fingers 114 from a center of a bottomof the substrate holder 110 may be substantially uniform.

The substrate holder 110 may have more than four holding fingers 114.According to some embodiments, the substrate holder 110 may have eightholding fingers 114. According to some embodiments, the substrate holder110 may have an odd number of holding fingers 114, e.g., five, seven,nine, eleven, thirteen, or fifteen holding fingers 114. According tosome embodiments, the number of holding fingers 114 may be thirty orless.

The holding fingers 114 may extend and be configured to reciprocate,e.g., move, in a direction substantially perpendicular to the secondsubstrate W2 (i.e., in the z direction). The reciprocation, e.g.,movement, of the holding fingers 114 may be implemented by holdingfinger actuators 114 a. Operations of the holding finger actuators 114 amay be controlled by a controller 140.

As shown in FIG. 2 , the holding finger actuators 114 a may beindependently electrically connected to the controller 140 and may beindependently controlled by the controller 140, e.g., the controller 140may control each finger actuator 114 a independently of the other fingeractuators 114 a. In other words, respective motions of, e.g., each of,the holding fingers 114 according to motions of the respective holdingfinger actuators 114 a may be independent from each other. This will bedescribed later in more detail. For example, multilayer piezoelectricactuators, voice coil motors (VCMs), or lag and pinion coupled with amotor may be used as the holding finger actuators 114 a, but embodimentsare not limited thereto.

A pressing finger 116 for pressing the second substrate W2 may beprovided on the center of the substrate holder 110, e.g., the holdingfingers 114 may surround the pressing finger 116. The pressing finger116 may be configured to reciprocate, e.g., move, in the directionsubstantially perpendicular to the second substrate W2 (i.e., in the zdirection). The reciprocation of the pressing finger 116 may beimplemented by a pressing finger actuator 116 a. An operation of thepressing finger actuator 116 a may be controlled by the controller 140.For example, a multilayer piezoelectric actuator, a VCM, or a lag andpinion coupled with a motor may be used as the pressing finger actuator116 a, but embodiments are not limited thereto.

A relative distance between the first substrate W1 and the secondsubstrate W2, e.g., along the z direction, may be sensed by a distancesensor 150, e.g., the distance sensor 150 may be positioned within thechamber housing 130 to face a space between the substrate holder 110 andthe substrate susceptor 120. According to some embodiments, the distancesensor 150 may measure a distance between the first substrate W1 and thesecond substrate W2 by perceiving images of the first substrate W1 andthe second substrate W2. According to some embodiments, the distancesensor 150 may measure the distance between the first substrate W1 andthe second substrate W2 by radiating electromagnetic waves to the firstsubstrate W1 and the second substrate W2 and then analyzingelectromagnetic waves reflected from the first substrate W1 and thesecond substrate W2. The distance sensor 150 recognizes the relativedistance between the first substrate W1 and the second substrate W2according to various methods, and embodiments are not limited to theabove-described methods.

According to some embodiments, each of the holding finger actuators 114a may have an arm shape. When the holding finger actuator 114 a is inthe shape of an arm, each of the holding fingers 114 is coupled to oneside of the arm. As the arm operates, the holding finger 114 may move inthe z direction.

FIGS. 3A through 3E are conceptual views of stages in a method ofbonding the first substrate W1 and the second substrate W2 together,according to an embodiment.

Referring to FIG. 3A, the substrate holder 110 having the secondsubstrate W2 held thereon may be arranged over the substrate susceptor120 having the first substrate W1 disposed thereon, so that the firstsubstrate W1 and the second substrate W2 are aligned with each other.For example, as illustrated in FIG. 3A, the first and second substratesW1 and W2 may be positioned to face each other with a predetermineddistance, e.g., a first distance d1, therebetween along the z direction.For example, as further illustrated in FIG. 3A, the distance sensor 150may be peripheral to, e.g., and between, the substrate holder 110 andthe substrate susceptor 120, and may face the distance between the firstand second substrates W1 and W2.

The substrate holder 110 may be moveable on an x-y plane to achieve thealignment, e.g., the controller 140 may move the substrate holder 110 inthe x direction and/or the y direction until the first and secondsubstrates W1 and W2 are aligned. According to some embodiments, analignment mark may be marked on the first substrate W1 and/or the secondsubstrate W2 in order to achieve the alignment, e.g., achieve alignmentof respective edges of the first and second substrates W1 and W2.

Moreover, the substrate holder 110 may be moveable in the z direction toachieve the alignment, e.g., the controller 140 may move the substrateholder 110 in the z direction until the first and second substrates W1and W2 are aligned and are parallel at the first distance d1. The firstdistance d1 between the first substrate W1 and the second substrate W2may be about 30 μm to about 100 μm. In this alignment step, when thefirst distance d1 is larger than about 100 μm, a bonding propagation(which will be described later) may be insufficient. On the other hand,when the first distance d1 is smaller than about 30 μm, the bondingpropagation may be excessive, and thus voids may be generated inbonding-propagated portions of the first and second substrates W1 andW2.

The alignment between the substrate holder 110 and the substratesusceptor 120 may be feedback-controlled, e.g., by a sensor systemincluding the distance sensor 150 and the controller 140. In anotherexample, an additional controller (other than the controller 140) may beused to control movement of the substrate holder 110 in the x direction,y direction, and z direction.

Referring to FIG. 3B, i.e., a first phase, the second substrate W2 maybe pressed toward the first substrate W1 by using the pressing finger116, e.g., only the pressing finger 116 may move toward the firstsubstrate W1 (along the arrow in FIG. 3B). At this time, the holdingfingers 114 of the substrate holder 110 may continuously hold the secondsubstrate W2, e.g., the holding fingers 114 may continuously maintainedges of the second substrate W2 at a stationary state while thepressing finger 116 pushes the center of the second substrate W2. As thepressing finger 116 presses the second substrate W2, the center of thesecond substrate W2 may contact the first substrate W1.

Referring to FIG. 3C, i.e., a second phase, a sufficient spontaneousbonding propagation between the first substrate W1 and the secondsubstrate W2 may be allowed. For example, referring to FIG. 3C, thespontaneous bonding propagation may spread from the centers of thecontacting first and second substrates W1 and W2, i.e., from the contactpoint between the first and second substrates W1 and W2 that overlapsthe pressing finger 116 (point O in FIG. 3C), towards edges of the firstand second substrates W1 and W2, e.g., along a second distance d2 in aradial direction.

In detail, according to some embodiments, respective surfaces of thefirst substrate W1 and the second substrate W2 that face each other mayhave been plasma-processed, e.g., before the beginning of the bondingprocess. In this case, electrostatic attraction occurs between thefacing surfaces of the first and second substrates W1 and W2, e.g., whenthe distance between the first and second substrates W1 and W2 issufficiently small. Accordingly, a bonding propagation may occur, so thefirst and second substrates W1 and W2 may gradually bond together alongthe second distance d2 due to the electrostatic attraction therebetween(e.g., from a center O to a bonding front BF in FIG. 3C). That is, dueto the bonding propagation, the respective surfaces of the two first andsecond substrates W1 and W2 may gradually bond together from initialcontact portions thereof even without special, e.g., further,application of an external force.

In this case, a boundary may be defined between the bonded and un-bondedportions of the first and second substrates W1 and W2. That is, theboundary, i.e., the bonding front BF, may be defined between a firstportion (a portion between points O and BF of FIG. 3C) where therespective surfaces of the two first and second substrates W1 and W2 arebonded to each other and a second portion (a portion to the right ofpoint BF of FIG. 3C) where the respective surfaces of the two first andsecond substrates W1 and W2 are not bond with each other.

If the holding fingers 114 were to stop holding the second substrate W2,and an edge of the second substrate W2 were to freely fall and contactan edge of the first substrate W1, the bonding front BF would havepropagated up to the edge of the first substrate W1 (or the secondsubstrate W2), e.g., too quickly and non-uniformly, thereby generatingvoids in bonding interface between the first and second substrates W1and W2. In contrast, referring to FIG. 3C, since the holding fingers114, according to embodiments, hold the second substrate W2, the bondingfront BF may not be propagated up to the edge of the first substrate W1(or the second substrate W2). The bonding front BF may be propagatedonly up to a position where attraction between the respective surfacesof the two first and second substrates W1 and W2 and an elasticrestoring force of the second substrate W2 balance.

If the first distance d1 between the edge of the second substrate W2 andthe edge of the first substrate W1 increases, the second distance d2between the center O and the bonding front BF may decrease. If the firstdistance d1 between the edge of the second substrate W2 and the edge ofthe first substrate W1 decreases, the second distance d2 between thecenter O and the bonding front BF may increase.

Referring to FIG. 3D, i.e., a third phase, the holding fingers 114 maydescend toward the first substrate W1 such that the edge of the secondsubstrate W2 bonds with the edge of the first substrate W1.Consequently, the first substrate W1 and the second substrate W2 may becompletely bonded with each other.

At this time, not all of the holding fingers 114 may move at the samespeed. Moreover, not all of the holding fingers 114 may move, e.g.,displaced by the same amount. In other words, the holding fingers 114may be independently controlled and independently operate, e.g., each ofthe holding fingers 114 may be independently controlled to move apredetermined distance along the z direction at a predetermined speed toachieve proper bonding between the first and second substrates W1 andW2.

In detail, a plurality of distance sensors 150 may be arranged aroundthe first substrate W1 and the second substrate W2. The plurality ofdistance sensors 150 measure distances between the first substrate W1and the second substrate W2 at their locations, respectively, andtransmit the measured distances to the controller 140 of FIG. 1 .

The controller 140 may calculate a distance between the first substrateW1 and the second substrate W2 at a location of each of the holdingfingers 114, by using distance information corresponding to thedistances between the first substrate W1 and the second substrate W2respectively measured by the distance sensors 150. The distance betweenthe first and second substrates W1 and W2 at the location of each of theholding fingers 114 may be calculated, via interpolation, from thedistance between the first and second substrates W1 and W2 at thelocation of each of the distance sensors 150. However, embodiments arenot limited to this.

The controller 140 may calculate a target location of each holdingfinger 114 for a next moment, e.g., a distance by which and a speed atwhich the holding finger 114 needs to move in the z direction, based onthe distance between the first and second substrates W1 and W2calculated at the location of the holding finger 114. Next, thecontroller 140 may transmit, to each of the holding finger actuators 114a of FIG. 1 , a signal for allowing each of the holding fingers 114 tomove to the calculated target location. In other words, the controller140 may be configured to calculate, in real time, the distance betweenthe first and second substrates W1 and W2 at the location of eachholding finger 114 and to control, in real time, a target position andan operating speed of the holding finger 114, based on the calculateddistance.

According to some embodiments, the holding fingers 114 may descendtoward the first substrate W1 at different speeds. For example, fourholding fingers 114 located in two intersecting directions from amongthe eight holding fingers 114 may descend at constant speeds, and theremaining four holding fingers 114 may descend at lower speeds than thedescending speeds of the former holding fingers 114.

According to some embodiments, the holding fingers 114 may descendtoward the first substrate W1 to different heights. For example, thefour holding fingers 114 located in two intersecting directions fromamong the eight holding fingers 114 may have distances of H from thefirst substrate W1 at an arbitrary moment when the four holding fingers114 descend, and the remaining four holding fingers 114 may havedistances of (H+δH) from the first substrate W1. In other words, whilethe eight holding fingers 114 are descending, a height difference of δHbetween the height of the four holding fingers 114 and the height of theremaining four holding fingers 114 may be kept constant.

Referring to FIG. 3E, i.e., a fourth phase, the holding of the secondsubstrate W2 may be released by the holding fingers 114. A method ofreleasing the holding of the second substrate W2 may vary according tothe method of holding the second substrate W2. If a suction unit isprovided to the holding fingers 114 and the second substrate W2 is heldby the suction unit, the holding may be released by equalizing aninternal pressure of the suction unit with a pressure of the outside. Ifpower supplied to the holding fingers 114 generates an electrostaticforce and the second substrate W2 is held by the electrostatic force,the holding may be released by interrupting the supply of power to theholding fingers 114. The holding-released holding fingers 114 may movein a direction away from the first substrate W1.

FIGS. 4A and 4B are conceptual views of stages in a method of bondingthe first substrate W1 and the second substrate W2 together, accordingto another embodiment. The bonding method according to the presentembodiment is common to the embodiment described above with reference toFIGS. 3A through 3E in terms of the operations of FIGS. 3A through 3C.Therefore, FIGS. 4A and 4B refer to operations performed after thosedescribed with reference to FIG. 3C.

Referring to FIG. 4A, the holding fingers 114 may move toward the firstsubstrate W1 until a third distance d3 between the respective edges ofthe first and second substrates W2 and W1 is about 1 μm to about 50 μm.The moving of the holding fingers 114 toward the first substrate W1 maybe accomplished by a cooperation between the distance sensors 150, thecontroller 140, and the holding finger actuators 114 a, as describedabove with reference to FIG. 3D. During this process, the bonding frontBF may be closer to the edge of the first substrate W1 than the bondingfront BF of FIG. 3C. A fourth distance d4 between the center O and thebonding front BF may also be greater than the second distance d2 of FIG.3C.

Referring to FIG. 4B, even when the edge of the second substrate W2 isapart from the edge of the first substrate W1, the holding of the secondsubstrate W2 may be released by the holding fingers 114. The method ofreleasing the holding of the second substrate W2 has been describedabove with reference to FIG. 3E, and thus a description thereof will beomitted.

When the holding of the second substrate W2 by the holding fingers 114is released, the bonding front BF spreads in a radial direction, i.e.,in a direction toward the edge of the first substrate W1, until the edgeof the second substrate W2 bonds to the edge of the first substrate W1.If, after the center of the second substrate W2 is pressed by thepressing finger 116 to contact the first substrate W1, the holding ofthe second substrate W2 were to be released without bringing the edge ofthe second substrate W2 close to the first substrate W1 by using theholding fingers 114, bonding between the first substrate W1 and thesecond substrate W2 would not have been sufficient, e.g., due to voidstherebetween.

FIGS. 5A through 5E are conceptual views of stages in a method ofbonding the first substrate W1 and the second substrate W2 together,according to another embodiment.

Referring to FIG. 5A, a substrate holder 110 a having the secondsubstrate W2 held thereon may be arranged on a substrate susceptor 120 ahaving the first substrate W1 held thereon such as to be aligned withthe substrate susceptor 120 a.

The substrate susceptor 120 a may have susceptor holding fingers 114 sin order to hold the first substrate W1. The substrate susceptor 120 amay include a susceptor pressing finger 116 s in order to press thefirst substrate W1. The susceptor holding fingers 114 s and thesusceptor pressing finger 116 s may be arranged at locations facing theholding fingers 114 and the pressing finger 116 of the substrate holder110 a, respectively. In other words, the number of susceptor holdingfingers 114 s may be equal to that of holding fingers 114.

The substrate holder 110 a and the substrate susceptor 120 a may moverelative to each other on the x-y plane in order to align the firstsubstrate W1 with the second substrate W2 and/or to align the susceptorholding fingers 114 s with the holding fingers 114.

The substrate holder 110 a and the substrate susceptor 120 a may moverelative to each other in the z direction in order to adjust a fifthdistance d5 between the first substrate W1 and the second substrate W2.The fifth distance d5 between the first substrate W1 and the secondsubstrate W2 may be about 30 μm to about 100 μm. When the fifth distanced5 is too big, a bonding propagation may be insufficient. On the otherhand, when the fifth distance d5 is too small, the bonding propagationmay be excessive, and thus voids may be generated in bonding-propagatedportions of the first and second substrates W1 and W2.

The alignment between the substrate holder 110 a and the substratesusceptor 120 a and the adjustment of the distance therebetween may befeedback-controlled by the controller 140 connected to the sensor systemincluding the distance sensors 150.

Referring to FIG. 5B, the pressing fingers 116 and 116 s of thesubstrate holder 110 a and the substrate susceptor 120 a may approacheach other to press the first substrate W1 and the second substrate W2toward each other. In other words, the second substrate W2 may bepressed toward the first substrate W1 by using the pressing finger 116of the substrate holder 110 a. The first substrate W1 may be pressedtoward the second substrate W2 by using the susceptor pressing finger116 s of the substrate susceptor 120 a. Respective centers of the firstsubstrate W1 and the second substrate W2 may contact each other due tothe pressing.

According to some embodiments, a distance by which each of the pressingfinger 116 and 116 s moves may be a half of the fifth distance d5between the two first and second substrates W1 and W2. However,embodiments are not limited thereto, and the distance by which thepressing finger 116 moves downward may be greater than the distance bywhich the susceptor pressing finger 116 s moves upward. According toanother embodiment, the distance by which the pressing finger 116 movesdownward may be less than the distance by which the susceptor pressingfinger 116 s moves upward.

Referring to FIG. 5C, a sufficient spontaneous bonding propagationbetween the first substrate W1 and the second substrate W2 may beallowed. For example, the bonding propagation may be conducted until adistance between the centers of the first and second substrates W1 andW2 and the bonding front BF becomes d6. This has been described abovewith reference to FIG. 3C, and thus a redundant description thereof willbe omitted.

Referring to FIG. 5D, the holding fingers 114 and the susceptor holdingfingers 114 s may approach each other such that the edge of the secondsubstrate W2 and the edge of the first substrate W1 bond together. Atthis time, the movements of the holding fingers 114 and the susceptorholding fingers 114 s may be controlled by the controller 140. A controlscheme of the controller 140 has been described above with reference toFIG. 3D, and thus a description thereof will not be repeated.

The holding fingers 114 and the susceptor holding fingers 114 s maymaintain holding the second substrate W2 and the first substrate W1,respectively, until the edge of the second substrate W2 and the edge ofthe first substrate W1 bond together.

Referring to FIG. 5E, after bonding between the second substrate W2 andthe first substrate W1 is completed, the holding fingers 114 may releasethe holding of the second substrate W2. This has been described abovewith reference to FIG. 3E, and thus a description thereof will not berepeated. The holding-released holding fingers 114 may be moved in adirection away from the first substrate W1.

According to the embodiment of FIGS. 5A through 5E, because the amountsby which the first and second substrates W1 and W2 are distorted, i.e.,pushed along the z direction, by the pressing fingers 116 and 116 s aresmall, more precise bonding is possible. Moreover, because both theholding fingers 114 holding the second substrate W2 and the susceptorholding fingers 114 s holding the first substrate W1 are activelycontrolled, the first substrate W1 and the second substrate W2 may bondwith each other more precisely.

FIGS. 6A through 6E are conceptual views of stages in a method ofbonding the first substrate W1 and the second substrate W2 together,according to another embodiment.

Referring to FIG. 6A, the substrate holder 110 a having the secondsubstrate W2 held thereon may be arranged on a substrate susceptor 120 bhaving the first substrate W1 held thereon, such as to be aligned withthe substrate susceptor 120 b with a seventh distance d7 therebetween.This structure is the same as the embodiment described above withreference to FIG. 5A, and thus a description thereof will not berepeated.

Referring to FIG. 6B, the susceptor pressing finger 116 s of thesubstrate susceptor 120 b may contact the first substrate W1 withoutsubstantially pressing the first substrate W1 upward. This is to supportdownward pressing of the second substrate W2 as will be described later.

The pressing finger 116 of the substrate holder 110 a may press thesecond substrate W2 downward. The second substrate W2 may be presseddownward by the pressing finger 116 until the second substrate W2contacts the first substrate W1. Because the first substrate W1 issupported by the susceptor pressing finger 116 s, even when a pressureof the pressing finger 116 is applied to the first substrate W1, thefirst substrate W1 may not be substantially distorted.

Referring to FIG. 6C, a sufficient spontaneous bonding propagationbetween the first substrate W1 and the second substrate W2 may beallowed. For example, the bonding propagation may be conducted until adistance between the center of the first and second substrates W1 and W2and the bonding front BF becomes an eight distance d8. This has beendescribed above with reference to FIG. 3C, and thus a descriptionthereof will not be repeated.

Referring to FIG. 6D, the holding fingers 114 may be brought close tothe susceptor holding fingers 114 s such that the respective edges ofthe first and second substrates W1 and W2 bond to each other. Themovement of the holding fingers 114 may be controlled by the controller140. The control scheme of the controller 140 has been described abovewith reference to FIG. 3D, and thus a description thereof will not berepeated. The holding fingers 114 may continue holding the secondsubstrate W2 until the respective edges of the first and secondsubstrates W1 and W2 bond to each other.

Referring to FIG. 6E, after boning between the second substrate W2 andthe first substrate W1 is completed, the holding fingers 114 may releasethe holding of the second substrate W2. This has been described abovewith reference to FIG. 3E, and thus a description thereof will not berepeated. The holding-released holding fingers 114 may be moved in adirection away from the first substrate W1.

FIG. 7 is a conceptual view illustrating occurrence of distortion on asubstrate when, after a bonding front is formed, holding of the secondsubstrate W2 is released without bringing the edge of the secondsubstrate W2 close to the first substrate W1 by using the holdingfingers 114.

As shown in FIG. 7 , the entire substrate is distorted, and, inparticular, is distorted with specific directivity and in a(+)-character shape. This distortion may occur because of a crystalstructure of the substrate and may occur when a single crystalsubstrate, e.g., a silicon substrate, is used. In detail, a [100] or[010] crystal direction (i.e., crystallographic direction) may be adirection of 45° from an [110] crystal direction. A stress in the [110]crystal direction may be less than that of each of the [100] and [010]crystal directions. Accordingly, distortion in the [110] crystaldirection may be less than distortion in each of the [100] and [010]crystal directions.

On the other hand, according to embodiments, when, after a bonding frontis formed, the edge of the second substrate W2 is brought close to thefirst substrate W1 by the holding fingers 114 and then the holding ofthe second substrate W2 is released, distortion in the (+)-charactershape may be significantly reduced.

When the number of holding fingers 114 is greater than 4, an influenceaccording to a crystal direction may be reduced, and thus distortion inthe (+)-character shape may be reduced. According to some embodiments,when the number of holding fingers 114 is a multiple of 4, such as 8,12, or 16, a deviation of an azimuthal direction may be reduced. Thus,these embodiments may be favorable. According to some embodiments, whenthe number of holding fingers 114 is an odd number, such as 5, 7, or 9,a tendency toward occurrence of distortion that is symmetrical about thecenter of the substrate may be reduced. Thus, these embodiments may befavorable.

FIG. 8 is a schematic diagram illustrating a method of aligning thefirst substrate W1 with the second substrate W2, according to anembodiment.

Referring to FIG. 8 , the second substrate W2 may be disposed over thefirst substrate W1, while the first substrate W1 and the secondsubstrate W2 are not parallel to each other. In this case, to bond thefirst substrate W1 and the second substrate W2 together, arrangement ofthe first substrate W1 and the second substrate W2 in parallel to eachother may be first needed. In other words, before the first substrate W1and the second substrate W2 contact each other to bond together, theymay be arranged in parallel to each other according to a method whichwill now be described.

A plurality of distance sensors 150 may be arranged around the firstsubstrate W1. Although three distance sensors 150 are disposed in FIG. 8, four or more distance sensors 150 may be disposed.

As described above with reference to FIG. 3D, each distance sensor 150may measure a distance between the first substrate W1 and the secondsubstrate W2 at its location. Because the first substrate W1 and thesecond substrate W2 are not parallel to each other, distances betweenthe first substrate W1 and the second substrate W2 respectively measuredby the distance sensors 150 may be different from each other. Thecontroller 140 may estimate a distance between the first substrate W1and the second substrate W2 at a location of each of the holding fingers114, from the distances between the first substrate W1 and the secondsubstrate W2 respectively measured by the distance sensors 150.

The controller 140 may calculate how much each holding finger 114 is tomove in the z direction to arrange the first substrate W1 and the secondsubstrate W2 in parallel to each other, by using the estimated distancebetween the first substrate W1 and the second substrate W2. Thecontroller 140 transmits the calculated values to the holding fingeractuators 114 a of the holding fingers 114, respectively, and theholding finger actuators 114 a operate according to the receivedcalculated values and thus the first substrate W1 and the secondsubstrate W2 may be arranged in parallel to each other.

In FIG. 8 , an arrow shown beside each of the holding fingers 114indicates an exemplary distance, e.g., and direction, by which each ofthe holding fingers 114 needs to move in order to arrange the firstsubstrate W1 and the second substrate W2 in parallel to each other.Bigger arrows among the shown arrows indicate that the holding fingers114 need to move longer distances. Although an orientation of the secondsubstrate W2 is adjusted in FIG. 8 , one of ordinary skill in the artmay understand that the same result may be obtained due to adjustment ofan orientation of the first substrate W1 or orientations of the firstsubstrate W1 and the second substrate W2.

When a comparative substrate bonding apparatus, i.e., without holdingfingers 114, is used and the first substrate and the second substrateare not parallel to each other, a special, e.g., separate, unit formaking them parallel to each other is needed. In contrast, whensubstrate bonding apparatuses according to embodiments are used and thefirst substrate W1 and the second substrate W2 are not parallel to eachother, the plurality of holding fingers 114, e.g., which are within thesubstrate bonding apparatuses, may adjust positions of the first andsecond substrates W1 and W2 to make them parallel to each other. Thus,the aforementioned special unit employed in the comparative substratebonding apparatus is not needed, and the substrate bonding apparatusesaccording to embodiments may have simplified structures.

FIG. 9 is a side view of a holding finger 114 v according to anembodiment. The holding finger 114 v may be substantially similar to theholding finger 114 in FIGS. 1-8 .

Referring to FIG. 9 , the holding finger 114 v may have a fluid passage114 h that communicates with an end 114 t. When the end 114 t contactsthe second substrate W2, the fluid passage 114 h may be isolated fromthe outside of the holding finger 114 v. When an internal pressure ofthe fluid passage 114 h is lower than an external pressure of theholding finger 114 v, the second substrate W2 may be attached to theholding finger 114 v with a strength that is proportional to adifference between the two pressures.

When holding of the second substrate W2 is intended to be released, theholding may be released by making the internal pressure of the fluidpassage 114 h equal to or almost equal to the external pressure of theholding finger 114 v. To this end, a fluid may be supplied to the fluidpassage 114 h via a special passage.

The end 114 t may be formed of an elastic material such that the holdingfinger 114 v and the second substrate W2 may more smoothly adhere toeach other and thus may be more tightly attached to each other. Forexample, the end 114 t may be formed of any suitable polymer materialhaving elasticity. When the end 114 t is formed of an elastic material,damage of the second substrate W2 may be reduced.

FIG. 10 is a side view of a holding finger 114 e according to anotherembodiment. Any of the embodiments in FIGS. 1-8 may employ fingers 114 einstead of fingers 114 or 114 v.

Referring to FIG. 10 , the holding finger 114 e may include anelectrostatic device 114 es capable of generating an electrostaticforce, around an end 114 t of the holding finger 114 e. Theelectrostatic device 114 es may generate the electrostatic force byapplying power, and the second substrate W2 may be attached to theholding finger 114 v by the electrostatic force. Accordingly, whensupply of the power to the electrostatic device 114 es is interrupted,the holding of the second substrate W2 may be immediately released.

FIG. 11 is a side view of a holding finger 114 f according to anotherembodiment. Any of the embodiments in FIGS. 1-8 may employ fingers 114 finstead of fingers 114, 114 v, or 114 e.

Referring to FIG. 11 , the holding finger 114 f may include a firstportion 114_1 extending in a direction perpendicular to a main surfaceof the second substrate W2, and a second portion 114_2 extending in adirection parallel to the main surface of the second substrate W2. Thesecond portion 114_2 may include the end 114 t of the holding finger 114f. In other words, the second portion 114_2 may directly contact thesecond substrate W2.

According to some embodiments, the fluid passage 114 h described abovewith reference to FIG. 9 may be provided within the holding finger 114f. In this case, a plurality of through holes may be provided on abottom surface of the second portion 114_2 and may communicate with thefluid passage 114 h.

According to some embodiments, the electrostatic device 114 es describedabove with reference to FIG. 10 may be provided within the holdingfinger 114 f. In this case, the electrostatic device 114 es may beprovided within the second portion 114_2.

Because the second portion 114_2 of the holding finger 114 f extends ina horizontal direction (i.e., the direction parallel to the main surfaceof the second substrate W2), a contact area between the holding finger114 f and the second substrate W2 may be increased, and the secondsubstrate W2 may be held with a more uniform pressure.

FIG. 12 is a side view of a substrate bonding apparatus 100 h accordingto another embodiment. The substrate bonding apparatus 100 h of FIG. 12is the same as the substrate bonding apparatus 100 of FIG. 1 , exceptthat a pressing finger 116 h is the same as the holding fingers 114.Accordingly, a description of FIG. 12 that is the same as given abovewith reference to FIG. 1 will not be repeated herein, and a differencetherebetween will now be mainly described.

Referring to FIG. 12 , the pressing finger 116 h may be configured tohold the second substrate W2. A principle that the pressing finger 116 hholds the second substrate W2 may be the same as the holding fingers114.

As substrates have become recently larger and thinner, when only theedge of a substrate is held, a center portion of the substrate may sagdownward due to a load of the substrate. This may cause the secondsubstrate W2 to be, e.g., damaged while being handled. Accordingly, whenthe pressing finger 116 h located at the center of the second substrateW2 holds the center portion of the second substrate W2, sagging of thesubstrate during substrate handling may be greatly reduced.

In a substrate bonding apparatus and a substrate bonding methodaccording to embodiments, precision of bonding substrates together maybe increased, and thus a semiconductor device may be manufactured withhigher precision. Moreover, the yield of a product is improved due tothe higher precision, and thus manufacturing costs thereof are reduced.

FIG. 13 is a schematic diagram illustrating the first substrate W1 andthe second substrate W2 bonded with each other, according to anembodiment. FIG. 14 is a magnified cross-sectional view of a portion XIIof FIG. 13 .

Referring to FIG. 13 , the first substrate W1 may include firstsemiconductor devices 20 on a surface thereof, and the second substrateW2 may include second semiconductor devices 30 on a surface thereof. Thefirst semiconductor devices 20 and the second semiconductor devices 30may bond with each other to constitute an integrated semiconductordevice, e.g., a CMOS image sensor (CIS).

Referring to FIG. 14 , a first semiconductor device 20 may include atransistor Tr having a gate electrode 255 and source and drain regions251 on a semiconductor substrate 201, e.g., single crystal silicon. Thegate electrode 255 may be electrically connected to a layer over thegate electrode 255, via first buried wires 259. The first buried wires259 may each include a first barrier metal layer 259 a and a first metallayer 259 b, and may be insulated from each other by a first interlayerinsulation layer 257.

Other intermediate wiring layers may include buried wires 265 and 268,each including a barrier metal layer and a metal layer, and interlayerinsulation layers 263 and 266 that surround the buried wires 265 and 268to insulate them from each other. The wiring layers may be separatedfrom each other by diffusion prevention layers 261, 281, and 269, exceptfor portions of the buried wires in each wiring layer that contact eachother.

A second semiconductor device 30 may include a transistor Tr having agate electrode 327 and source and drain regions 323 on a semiconductorsubstrate 301, e.g., single crystal silicon. The gate electrode 327 maybe electrically connected to a layer below the gate electrode 327, viasecond buried wires 331. The second buried wires 331 may each include asecond barrier metal layer 331 a and a second metal layer 331 b, and maybe insulated from each other by a second interlayer insulation layer329.

Other intermediate wiring layers may include buried wires 338, eachincluding a barrier metal layer and a metal layer, and an interlayerinsulation layer 335 that surrounds the buried wires 338 to insulatethem from each other. Optoelectric conversion units 321 may be providedwithin the semiconductor substrate 301.

As shown in FIG. 14 , the first substrate W1 and the second substrate W2may bond together such that the first semiconductor device 20 and thesecond semiconductor device 30 are connected to each other with theburied wires 268 of the first semiconductor device 20 and the buriedwires 338 of the second semiconductor device 30 facing each other.

Line widths of buried wires have become greatly thinner due to recenttrends toward miniaturization of semiconductor devices. To bond thesemiconductor devices together to have appropriate electricalcharacteristics, precision of several nanometers or less, e.g., about 40nm or less, is needed. Therefore, when the substrate bonding apparatusand the substrate bonding method described above with reference to FIGS.1 through 4B, FIG. 8 , and FIG. 12 are used, a semiconductor device maybe manufactured with higher precision.

The methods and processes described herein may be performed by code orinstructions to be executed by a computer, processor, manager, orcontroller. Because the algorithms that form the basis of the methods(or operations of the computer, processor, or controller) are describedin detail, the code or instructions for implementing the operations ofthe method embodiments may transform the computer, processor, orcontroller into a special-purpose processor for performing the methodsdescribed herein.

Also, another embodiment may include a computer-readable medium, e.g., anon-transitory computer-readable medium, for storing the code orinstructions described above. The computer-readable medium may be avolatile or non-volatile memory or other storage device, which may beremovably or fixedly coupled to the computer, processor, or controllerwhich is to execute the code or instructions for performing the methodembodiments described herein.

By way of summation and review, embodiments provide a substrate bondingapparatus and a substrate bonding method capable of manufacturing asemiconductor device at low costs and with improved precision. That is,embodiments provide independently controlled holding fingers as part ofa substrate holder for holding a substrate. The holding fingers movetoward a lower substrate until an edge of an upper substrate contactsthe lower substrate, and, after the upper substrate and the lowersubstrate bond together, holding is released, e.g., as opposed to acomparative apparatus that causes an edge of the substrate to freelyfall due to release of the holding when edges of substrates are farapart from each other. Moreover, while the holding fingers are beingindependently controlled, a bonding front situation (distance betweensubstrates) of a substrate is ascertained in real time, and a movingspeed, a displacement, and the like of the holding fingers arecontrolled by reflecting the bonding front situation.

Example embodiments have been disclosed herein, and although specificterms are employed, they are used and are to be interpreted in a genericand descriptive sense only and not for purpose of limitation. In someinstances, as would be apparent to one of ordinary skill in the art asof the filing of the present application, features, characteristics,and/or elements described in connection with a particular embodiment maybe used singly or in combination with features, characteristics, and/orelements described in connection with other embodiments unless otherwisespecifically indicated. Accordingly, it will be understood by those ofskill in the art that various changes in form and details may be madewithout departing from the spirit and scope of the present invention asset forth in the following claims.

What is claimed is:
 1. A substrate bonding apparatus, comprising: asubstrate susceptor to support a first substrate; a substrate holderover the substrate susceptor to hold a second substrate, the substrateholder including a plurality of holding fingers, and the plurality ofholding fingers being independently moveable a predetermined distancealong a direction perpendicular to the substrate holder; a chamberhousing to accommodate the substrate susceptor and the substrate holder;a distance sensor to measure a distance between an edge of the firstsubstrate and an edge of the second substrate; a controller to controlthe plurality of holding fingers, based on the distance sensed by thedistance sensor; and a plurality of holding finger actuators to positionthe plurality of holding fingers, respectively, based on the control ofthe controller.
 2. The substrate bonding apparatus as claimed in claim1, wherein the substrate holder includes at least eight holding fingers,and the first substrate and the second substrate are silicon wafers. 3.The substrate bonding apparatus as claimed in claim 1, wherein theplurality of holding fingers are independently controlled to physicallymove toward and away from the substrate susceptor.
 4. The substratebonding apparatus as claimed in claim 1, wherein the controller is toreceive the distance sensed by the distance sensor, calculate a targetlocation of each of the plurality of holding fingers based on thereceived distance, and transmit, to the plurality of holding fingeractuators, a signal for moving each of the plurality of holding fingersto the target location.
 5. The substrate bonding apparatus as claimed inclaim 2, wherein the plurality of holding fingers are to hold the secondsubstrate on respective ends of the plurality of holding fingers byattraction formed on the respective ends of the plurality of holdingfingers.
 6. The substrate bonding apparatus as claimed in claim 5,wherein each of the plurality of holding fingers has a fluid passagethat communicates with each of the ends of the plurality of holdingfingers, the attraction being formed by maintaining an internal pressureof the fluid passage to be lower than an ambient pressure.
 7. Thesubstrate bonding apparatus as claimed in claim 5, wherein: theplurality of holding fingers are to hold the second substrate onrespective ends of the plurality of holding fingers via electrostaticattraction, and the plurality of holding fingers are to apply anelectrostatic force to the second substrate and release theelectrostatic force from the second substrate to control application ofthe electrostatic attraction.
 8. The substrate bonding apparatus asclaimed in claim 2, wherein the substrate holder further includes apressing finger at a location corresponding to a center of the secondsubstrate, the pressing finger to press the second substrate toward thefirst substrate.
 9. The substrate bonding apparatus as claimed in claim8, wherein: the at least eight holding fingers are along an edge of thesubstrate holder, the at least eight holding fingers surrounding thepressing finger, and the pressing finger and the at least eight holdingfingers are independently controllable and moveable, the pressing fingerto press only the center of the second substrate toward the firstsubstrate, and the plurality of holding fingers to hold the edge of thesecond substrate stationary during a first phase.
 10. The substratebonding apparatus as claimed in claim 9, wherein the substrate holder isto allow a spontaneous bonding propagation between the first substrateand the second substrate to be sufficiently conducted during a secondphase subsequent to the first phase.
 11. The substrate bonding apparatusas claimed in claim 10, wherein the plurality of holding fingers aremoveable toward the first substrate during a third phase subsequent tothe second phase, in order for the edge of the second substrate to bondwith the edge of the first substrate.
 12. The substrate bondingapparatus as claimed in claim 8, wherein the substrate susceptorincludes: a plurality of susceptor holding fingers arranged at locationscorresponding to the plurality of holding fingers, the plurality ofsusceptor holding fingers being individually and independently moveable;and a susceptor pressing finger at a location corresponding to a centerof the first substrate, the susceptor pressing finger to press the firstsubstrate toward the second substrate.
 13. The substrate bondingapparatus as claimed in claim 12, wherein the susceptor pressing fingeris to press the first substrate such that the first substrate contactsthe second substrate while the plurality of susceptor holding fingersare holding the first substrate during a first phase.
 14. The substratebonding apparatus as claimed in claim 1, wherein each of the pluralityof holding fingers includes an elastic member at an end thereof, theelastic member to contact the second substrate.
 15. The substratebonding apparatus as claimed in claim 1, wherein: each of the pluralityof holding fingers includes a first portion extending in a directionperpendicular to a main surface of the second substrate and a secondportion extending in a direction parallel to the main surface of thesecond substrate, and the second portion includes an end of each of theplurality of holding fingers.
 16. A substrate bonding apparatus,comprising: a substrate susceptor to support a first substrate; asubstrate holder over the substrate susceptor to hold a secondsubstrate, the substrate holder including holding fingers independentlymoveable a predetermined distance along a direction perpendicular to thesubstrate holder; a pressing finger at a center of the substrate holder,the pressing finger being moveable toward the substrate susceptor topress the second substrate toward the first substrate; a distance sensorto measure a distance between an edge of the first substrate and an edgeof the second substrate; a controller to control the plurality ofholding fingers, based on the distance sensed by the distance sensor;and a plurality of holding finger actuators to position the plurality ofholding fingers, respectively, based on the control of the controller,wherein the substrate holder is to release holding the second substrateafter a spontaneous bonding propagation between the first substrate andthe second substrate is sufficiently conducted and the edge of thesecond substrate approaches the edge of the first substrate.
 17. Thesubstrate bonding apparatus as claimed in claim 16, wherein: thesubstrate holder includes at least eight holding fingers along an edgeof the substrate holder, the at least eight holding fingers and pressingfinger being independently controllable, and the pressing finger is topress a center of the second substrate toward the first substrate tocontact the first substrate, while the holding fingers are to maintainthe edge of the second substrate stationary, in order to conduct thespontaneous bonding propagation.
 18. The substrate bonding apparatus asclaimed in claim 17, wherein the holding fingers are independentlycontrollable to be physically moveable toward and away from thesubstrate susceptor.
 19. A substrate bonding apparatus, comprising: asubstrate susceptor to support a first substrate; a substrate holderover the substrate susceptor to hold a second substrate, the substrateholder including holding fingers independently moveable a predetermineddistance along a direction perpendicular to the substrate holder; and apressing finger at a center of the substrate holder, the pressing fingerbeing moveable toward the substrate susceptor to press the secondsubstrate toward the first substrate; a distance sensor to measure adistance between an edge of the first substrate and an edge of thesecond substrate; a controller to control the plurality of holdingfingers, based on the distance sensed by the distance sensor; and aplurality of holding finger actuators to position the plurality ofholding fingers, respectively, based on the control of the controller,wherein the substrate holder is to release holding the second substrateafter a spontaneous bonding propagation between the first substrate andthe second substrate is sufficiently conducted and the edge of thesecond substrate approaches the edge of the first substrate, and whereinthe substrate holder is to release holding of the second substrate aftermoving toward the first substrate until a distance between the edge ofthe second substrate and the edge of the first substrate is about 1 μmto about 50 μm.